FU(STI)-17

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

3. Intake Manifold

A: REMOVAL

1) Remove the V-belt covers.

2) Collect the refrigerant from A/C system. <Ref. to

AC-26, PROCEDURE, Refrigerant Recovery Pro-

cedure.>

3) Release the fuel pressure. <Ref. to FU(STI)-64,

RELEASING OF FUEL PRESSURE, PROCE-

DURE, Fuel.>

4) Disconnect the ground cable from battery.

5) Open the fuel filler lid and remove the fuel filler

cap.

NOTE:

This operation is required to release the inner pres-

sure of the fuel tank.

6) Lift up the vehicle.

7) Remove the under cover. <Ref. to EI-21, RE-

MOVAL, Front Under Cover.>

8) Drain approximately 3.0 L (3.2 US qt, 2.6 Imp qt)

of coolant. <Ref. to CO(STI)-13, DRAINING OF

ENGINE COOLANT, REPLACEMENT, Engine

Coolant.>

9) Remove the air intake duct. <Ref. to IN(STI)-11,

REMOVAL, Air Intake Duct.>

10) Remove the chamber assembly. <Ref. to

IN(STI)-22, REMOVAL, Chamber Assembly.>

11) Remove the intercooler. <Ref. to IN(STI)-13,

REMOVAL, Intercooler.>

12) Remove the air intake boot.

13) Remove the air by-pass valve. <Ref. to

IN(STI)-20, REMOVAL, Air By-pass Valve.>

14) Remove the generator. <Ref. to SC(STI)-15,

REMOVAL, Generator.>

15) Remove the coolant filler tank. <Ref. to

CO(STI)-28, REMOVAL, Coolant Filler Tank.>

16) Disconnect the A/C pressure hoses from A/C

compressor. <Ref. to AC-63, REMOVAL, Hose and

Pipe.>

17) Disconnect the engine coolant hose from throt-

tle body.

18) Disconnect the brake booster vacuum hose (A)

and pressure regulator vacuum hose (B) from the

intake manifold.

19) Disconnect the connector from the PCV hose

assembly A.

FU-03487

IN-03564

FU-05761

ME-05007

E N G

(A)

(B)

FU-08341

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FU(STI)-18

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

20) Remove the PCV hose assembly A from clip

(A), and remove the vacuum hose from clip (B).

21) Disconnect the vacuum hose (A) and the con-

nector (B) from the PCV hose assembly B.

22) Disconnect the air control hose (A) from the

waste gate actuator, and loosen the clamp which

holds the intake duct to the turbocharger.

23) Remove the engine coolant hose from the wa-

ter tank pipe.

24) Remove the engine harness from clip (A).

25) Disconnect the bulkhead harness connectors

from the engine harness connectors.

26) Lift the claw (A) and remove the engine har-

ness connector from the engine harness bracket.

27) Disconnect the connector (A) from the engine

coolant temperature sensor, connector (B) from the

oil pressure switch, and connector (C) from the

crankshaft position sensor.

28) Disconnect the connector from power steering

pump switch.

FU-08342

(A)

(B)

(A)

(B)

FU-08343

FU-04384

(A)

FU-06569

FU-06570

(A)

FU-08327

(A)

(C)

(A)

(B)

FU-05725

FU-04598

15WRX_STI_US_EN.book 18 ページ２０１５年２月１３日　金曜日　午前１１時２０分

FU(STI)-19

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

29) Disconnect the connector from the knock sen-

sor.

30) Disconnect the connector from the secondary

air combination valve.

31) Disconnect the connector from the intake cam-

shaft position sensor.

32) Disconnect the connector from the intake oil

flow control solenoid valve.

33) Lift up the vehicle.

34) Remove the engine harness cover. (right side

only.)

35) Remove the clip holding the engine harness.

(Left side only)

FU-03492

FU-03493

FU-04385

FU-03495

FU-03616

FU-08481

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FU(STI)-20

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

36) Disconnect connector (A) from the exhaust

camshaft position sensor, connector (B) from the

exhaust oil flow control solenoid valve, and connec-

tor (C) from the ignition coil.

37) Lower the vehicle.

38) Remove the clip (A) which hold the engine har-

ness to the rocker cover RH.

39) Remove the bolts that secure the air duct to the

rocker cover LH, and remove the engine harness.

40) Disconnect the fuel delivery hose, fuel return

hose and evaporation hose.

CAUTION:

• Be careful not to spill fuel.

• Catch the fuel from hoses using a container

or cloth.

(1) Set the ST to the fuel pipe.

ST 42099AE000 QUICK CONNECTOR RE-

LEASE

(2) Disconnect the quick connector of the fuel

delivery hose and fuel return hose by pushing

the ST in the direction of the arrow.

(3) Remove the clip and disconnect the evapo-

ration hose from the fuel pipe.

41) Remove the intake manifold from cylinder

head.

FU-05746

(B)

(C)

(A)

(C)

(A)

(B)

FU-03581

(A)

FU-06573

(A) Fuel delivery hose

(B) Fuel return hose

ME-05008

(A)

(B)

(C)

FU-06574

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FU(STI)-21

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

B: INSTALLATION

1) Install the intake manifold onto cylinder heads.

NOTE:

Use a new gasket.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

2) Connect the fuel delivery hose, fuel return hose,

and evaporation hose.

3) Fix the engine harness to the rocker cover LH

with the air duct.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

4) Fix the engine harness to the rocker cover RH

with clips (A).

5) Lift up the vehicle.

6) Connect connector (A) to the exhaust camshaft

position sensor, connector (B) to the exhaust oil

flow control solenoid valve, connector (C) to the ig-

nition coil.

(A) Fuel delivery hose

(B) Fuel return hose

FU-06574

FU-05783

(A)

(B)

(C)

FU-06573

FU-03581

(A)

FU-05746

(B)

(C)

(A)

(C)

(A)

(B)

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FU(STI)-22

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

7) Install the engine harness cover. (right side

only.)

Tightening torque:

5 N·m (0.5 kgf-m, 3.7 ft-lb)

8) Install the clip securing the engine harness. (Left

side only)

9) Lower the vehicle.

10) Connect the connector to the intake oil flow

control solenoid valve.

11) Connect the connector to the intake camshaft

position sensor.

12) Connect the connector to the secondary air

combination valve.

13) Connect the connector to the knock sensor.

FU-03616

FU-08481

FU-03495

FU-04385

FU-03493

FU-03492

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FU(STI)-23

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

14) Connect the connector to the power steering

pump switch.

15) Connect the connector (A) to the engine cool-

ant temperature sensor, connector (B) to the oil

pressure switch, and the connector (C) to the

crankshaft position sensor.

16) Install the engine harness connector to engine

harness bracket, then connect the bulkhead har-

ness connector to the engine harness connector.

17) Install the engine harness to clip (A).

18) Install the engine coolant hose to the water

tank pipe.

19) Connect the air control hose (A) to the waste-

gate actuator, and install the turbocharger to the in-

take duct.

Tightening torque:

3 N·m (0.3 kgf-m, 2.2 ft-lb)

20) Connect the vacuum hose (A) and connector

(B) to the PCV hose assembly B.

21) Install the vacuum hose to clip (B), and install

the PCV hose assembly A to clip (A).

FU-04598

(C)

(A)

(B)

FU-05725

FU-08417

FU-06570

(A)

FU-06569

FU-04384

(A)

(B)

FU-08343

FU-08342

(A)

(B)

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FU(STI)-24

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

22) Connect the connector to the PCV hose as-

sembly A.

23) Connect the brake booster vacuum hose (A)

and pressure regulator vacuum hose (B) to the in-

take manifold.

24) Connect the engine coolant hoses to throttle

body.

25) Install the A/C pressure hoses to A/C compres-

sor. <Ref. to AC-67, INSTALLATION, Hose and

Pipe.>

26) Install the coolant filler tank. <Ref. to CO(STI)-

28, INSTALLATION, Coolant Filler Tank.>

27) Install the generator. <Ref. to SC(STI)-15, IN-

STALLATION, Generator.>

28) Install the air by-pass valve. <Ref. to IN(STI)-

20, INSTALLATION, Air By-pass Valve.>

29) Install the air intake boot.

Tightening torque:

2.5 N·m (0.3 kgf-m, 1.8 ft-lb)

30) Install the intercooler. <Ref. to IN(STI)-14, IN-

STALLATION, Intercooler.>

31) Install the chamber assembly. <Ref. to IN(STI)-

22, INSTALLATION, Chamber Assembly.>

32) Install the air intake duct. <Ref. to IN(STI)-11,

INSTALLATION, Air Intake Duct.>

33) Connect the battery ground terminal.

34) Lift up the vehicle.

35) Install the under cover. <Ref. to EI-22, INSTAL-

LATION, Front Under Cover.>

36) Lower the vehicle.

37) Install the V-belt cover.

Tightening torque:

13 N·m (1.3 kgf-m, 9.6 ft-lb)

38) Fill engine coolant. <Ref. to CO(STI)-13, FILL-

ING OF ENGINE COOLANT, REPLACEMENT,

Engine Coolant.>

39) Charge the A/C system with refrigerant. <Ref.

to AC-27, PROCEDURE, Refrigerant Charging

Procedure.>

FU-08341

ME-05007

E N G

(A)

(B)

FU-05761

IN-03564

FU-03487

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FU(STI)-25

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

C: DISASSEMBLY

1) Remove clamp (A) holding the fuel pipe protec-

tor RH to the engine harness, and remove the fuel

pipe protector RH.

2) Remove the fuel pipe protector LH.

3) Remove the connector from the intake duct.

4) Remove the connector from the PCV hose as-

sembly.

5) Remove purge control solenoid valve 1 (A) and

purge control solenoid valve 2 (B).

6) Disconnect the connector (A) from the waste-

gate control solenoid valve, and disconnect the

vacuum hose (B) from the intake duct.

7) Remove the solenoid valve bracket together with

the wastegate control solenoid valve.

8) Remove the engine ground terminals from the

intake manifold.

FU-06575

(A)

FU-06591

FU-05921

FU-06576

FU-06577

(A)

(B)

FU-06578

(A)

(B)

FU-06579

FU-03588

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FU(STI)-26

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

9) Disconnect the connector (A) from the throttle

position sensor, and the connector (B) from the

manifold pressure sensor.

10) Remove clip (A) holding the engine harness

and vacuum hose, clip (B) holding the engine har-

ness to the engine harness stay, and the bolt hold-

ing the engine harness to the intake manifold.

11) Remove the throttle body from the intake man-

ifold.

12) Remove the harness band (A) which holds the

engine harness to the fuel injector pipe.

• RH side

•LH side

13) Disconnect the connector from fuel injector.

14) Disconnect the connector from the tumble gen-

erator valve assembly.

15) Remove the bolts which hold fuel injector pipe.

•RH side

FU-05918

(B)

(A)

FU-03565

(A)

(B)

FU-05692

FU-05919

(A)

FU-05920

(A)

FU-03508

FU-04604

FU-03512

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FU(STI)-27

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

•LH side

16) Remove the fuel injector.

17) Remove the harness brackets holding the en-

gine harness to the intake manifold, and remove

the engine harness.

18) Loosen the clamp holding the RH side fuel

hose to the fuel injector pipe RH, and remove the

fuel injector pipe RH.

19) Loosen the clamp holding the LH side fuel hose

to the fuel injector pipe LH, and remove the fuel in-

jector pipe LH.

20) Remove the bolts holding the fuel pipe assem-

bly to the intake manifold, and remove the fuel pipe

assembly.

21) Remove the intake duct from intake manifold.

FU-03594

FU-03595

FU-03513

FU-03567

FU-04605

FU-04606

FU-00051

FU-06580

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FU(STI)-28

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

22) Remove the tumble generator valve assembly

from the intake manifold.

23) Remove the nipple from the intake manifold.

D: ASSEMBLY

1) Apply liquid gasket to the nipple threads, and in-

stall the nipple to the intake manifold.

Liquid gasket:

THREE BOND 1105 (Part No. 004403010) or

equivalent

Tightening torque:

T1: 17 N·m (1.7 kgf-m, 12.5 ft-lb)

T2: 25 N·m (2.5 kgf-m, 18.4 ft-lb)

2) Install the tumble generator valve assembly onto

intake manifold.

NOTE:

Use a new gasket.

Tightening torque:

8.3 N·m (0.8 kgf-m, 6.1 ft-lb)

3) Install the air intake duct to the intake manifold.

Tightening torque:

17 N·m (1.7 kgf-m, 12.5 ft-lb)

4) Install the fuel pipe assembly to the intake man-

ifold.

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-03603

FU-05787

FU-05788

FU-03603

FU-06580

FU-00051

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FU(STI)-29

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

5) Install the fuel injector pipe LH and connect the

LH side fuel hose to the fuel injector pipe LH. <Ref.

to FU(STI)-99, CONNECTING FUEL DELIVERY

HOSE, FUEL RETURN HOSE AND FUEL HOSE,

INSTALLATION, Fuel Delivery, Return and Evapo-

ration Lines.>

6) Install the fuel injector pipe RH and connect the

RH side fuel hose to the fuel injector pipe RH. <Ref.

to FU(STI)-99, CONNECTING FUEL DELIVERY

HOSE, FUEL RETURN HOSE AND FUEL HOSE,

INSTALLATION, Fuel Delivery, Return and Evapo-

ration Lines.>

7) Install the engine harness to the intake manifold

and attach the harness brackets holding the engine

harness.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

8) Install the fuel injector.

NOTE:

Use new O-rings, rubbers and seal rings.

9) Install the bolts which hold fuel injector pipe.

•RH side

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

•LH side

Tightening torque:

6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

FU-04606

FU-04605

FU-03567

FU-03513

FU-03512

FU-03594

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FU(STI)-30

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

10) Connect the connector to the tumble generator

valve assembly.

11) Connect the connectors to the fuel injector.

12) Secure the engine harness to the fuel injector

pipe with the harness band (A).

• RH side

•LH side

13) Install the throttle body to the intake manifold.

NOTE:

Use a new gasket.

Tightening torque:

8 N·m (0.8 kgf-m, 5.9 ft-lb)

14) Secure the engine harness and vacuum hose

using the clip (A), and secure the engine harness to

the engine harness stay using the clip (B), and in-

stall the bolt which holds the engine harness to the

intake manifold.

Tightening torque:

19 N·m (1.9 kgf-m,14.0 ft-lb)

FU-03595

FU-04604

FU-03508

FU-05919

(A)

FU-05920

(A)

FU-05692

FU-03565

(A)

(B)

15WRX_STI_US_EN.book 30 ページ２０１５年２月１３日　金曜日　午前１１時２０分

FU(STI)-31

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

15) Connect connector (A) to the throttle position

sensor and connector (B) to the manifold pressure

sensor.

16) Install the engine ground terminal to intake

manifold.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

17) Install the solenoid valve bracket together with

the wastegate control solenoid valve.

Tightening torque:

T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

T2: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

18) Connect the vacuum hose (B) to the intake

duct, then connect the connector (A) to the waste-

gate control solenoid valve.

19) Install purge control solenoid valve 1 and purge

control solenoid valve 2.

NOTE:

Connect the vacuum hose and vacuum control

hose as shown in the figure.

FU-05918

(B)

(A)

FU-03588

FU-06581

(A) Purge control solenoid valve 1

(B) Purge control solenoid valve 2

(a) To intake duct

(b) To intake manifold

FU-06578

(A)

(B)

(c)

(b)

(a)

(B)

(A)

(c)

FU-04417

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FU(STI)-32

Intake Manifold

FUEL INJECTION (FUEL SYSTEMS)

Tightening torque:

T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

T2: 19 N·m (1.9 kgf-m, 14.0 ft-lb)

20) Attach the connector to the PCV hose assem-

bly.

21) Install the connector to the intake duct.

22) Install the fuel pipe protector LH.

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

23) Install the fuel pipe protector RH, and secure

the engine harness to the fuel pipe protector RH

using the clip (A).

Tightening torque:

19 N·m (1.9 kgf-m, 14.0 ft-lb)

E: INSPECTION

1) Check that the intake manifold and fuel pipe

have no deformation, cracks and other damages.

2) Check that the hose has no cracks, damage or

loose part.

FU-06582

FU-06576

FU-05921

FU-06591

FU-06575

(A)

15WRX_STI_US_EN.book 32 ページ２０１５年２月１３日　金曜日　午前１１時２０分